Brushroll having improved cleaning capability

ABSTRACT

A vacuum cleaner brushroll including a spindle, bristle tufts carried by the spindle, and sleeves fitted on the ends of the spindle, the bristle tufts including angled end tufts that extend through the sleeve outwardly beyond the ends of the spindle to provide a wide cleaning path and improved edge cleaning capability upon rotation of the brushroll. The sleeve on one end of the brushroll has a pulley.

[0001] This application is a continuation-in-part of Ser. No.09/974,354, filed on Oct. 10, 2001.

TECHNICAL FIELD

[0002] The present invention relates generally to vacuum cleaners, andmore specifically to a vacuum cleaner brushroll having improved cleaningcapability.

BACKGROUND ART

[0003] An example of a vacuum cleaner brushroll and a brushroll mountingassembly is disclosed in U.S. Pat. No. 5,272,785 dated Dec. 18, 1993,the disclosure of which is incorporated herein by reference. Thedisclosed brushroll mounting assemblies include stub shafts which arefixed in the ends of the brushroll spindle, bearings which have theirinner races press fitted on the projecting ends of the stub shafts, andouter end members, e.g. end caps, that receive the outer races of thebearings and serve as a means for mounting the brushroll in the mouth ofthe vacuum cleaner nozzle.

[0004] Certain prior art brushrolls include metal ferrules that embracethe outer ends of the spindle. In a typical construction, the stubshafts extend through center openings of the ferrules into the spindleends. The metal ferrules can have expanded end openings that receiveprojecting portions of the end caps in order to guard against threadsand dirt entering the bearings.

[0005] Conventional brushroll spindles have a pulley belt drive surfacenear one end and carry rows of bristle tufts which agitate the carpet toloosen the dirt as the brushroll is rotated. Typically, the rows ofbristle tufts terminate inwardly of the ends of a brushroll spindle.This is particularly true in the case of brushrolls which have metalferrules, since they cannot be drilled with conventional wood drills topermit tufting at the ends of the spindle. Thus, a brushroll with metalferrules at its ends necessarily has poor edge cleaning capability and acleaning path no longer than the length of the spindle.

SUMMARY OF THE INVENTION

[0006] The invention is a new and improved vacuum cleaner brushrollhaving bristle tufts that are angled outwardly to extend beyond the endsof the brushroll spindle. These angled end tufts widen the normalcleaning path of the brushroll, provide improved edge cleaningcapability, and enhance the overall cleaning characteristic of thebrushroll.

[0007] In the disclosed embodiments, a sleeve is press fitted over eachend of the brushroll spindle. The sleeves are made of plastic or othermaterial that can be drilled with a conventional wood drill to formangled tuft holes very near the ends of the spindle. The sleeves preventcracking or splitting of the spindle ends when they are drilled. Theangled end tufts are fixed in the holes and extend outwardly through thesleeves beyond the ends of the spindle.

[0008] Moisture changes in wooden spindles can cause shrinking andswelling of the wood. In many conventional constructions, swelling canresult in the pins or stub shafts which mount the spindle bearings fromloosening the holes of the spindle, thereby causing brushroll rattle andgeneral unsatisfactory operation. The end sleeves of the presentinvention avoid this difficulty. As the spindle swells against thesleeves, the wood is compressed to maintain a firm grip on the pins orstub shafts that are fitted in the ends of the spindle.

[0009] Another feature of the invention is an end sleeve as describedabove which includes a co-molded drive pulley that takes the place ofthe enlarged pulley drive surface heretofore formed as an integral partof the wooden spindle near one end. The pulley that is integrally madewith the end sleeve can be of any suitable shape that will coact withthe vacuum cleaner drive belt. For example, the pulley may have beltengaging grooves or it may be formed to coact with a timer belt drive.

[0010] In one disclosed embodiment, the brushroll further includes onepiece plastic ferrules at each end of the brushroll. Each ferrule has aperipheral skirt that embraces the end portion of the adjacent sleeve, ahollow pin that is pressed into the end of the spindle and receives thebearing mounting stub shaft, and a web connecting the pin and skirt.

[0011] Still other features, advantages and a fuller understanding ofthe invention will become apparent to those skilled in the art from thefollowing description of the preferred embodiments of the invention andthe accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012]FIG. 1 is a side elevational view of a brushroll according to oneembodiment of the invention;

[0013]FIG. 2 is an enlarged, fragmentary end view, partially incross-section, of the brushroll shown in FIG. 1;

[0014]FIG. 3 is a partially exploded end view of the end of thebrushroll shown in FIG. 2;

[0015]FIG. 4 is an elevational, fragmentary end view of a brushrollaccording to another embodiment of the invention;

[0016]FIG. 5 is a view similar to FIG. 4 partially in cross-section; and

[0017]FIG. 6 is a fragmentary end view, partially in cross-section, of abrushroll according to still another embodiment of the invention.

DESCRIPTION OF PREFERRED EMBODIMENTS

[0018] A brushroll 10 according to one embodiment of the presentinvention is shown in FIG. 1. It includes a wood spindle or dowel 20rotatably supported at each end by end assemblies 35. Each end assemblycan be mounted in the mouth of the vacuum cleaner nozzle (not shown) torotatably position the brushroll 10. In accordance with conventionalpractice, the spindle 20 carries rows of bristle tufts 30 which agitatethe carpet to loosen dirt as the brushroll is rotated.

[0019] The ends of the spindle or dowel 20 and the end assemblies 35 aresimilar. Accordingly, only one end of the brushroll 10 is shown anddescribed in detail. As illustrated in FIGS. 2 and 3, an axial hole 22is drilled in the end of the spindle and opens through the bottom wall23 of a countersunk mouth 24. An axially extending lip 25 surrounds themouth 24 and has an inner surface 26 and an outer surface 27.

[0020] As more fully disclosed in the above referenced U.S. Pat. No.5,272,785, each end assembly 35 includes a stub shaft 36, a bearing 37which has its inner race fitted on a projecting end of the stub shaft36, and an end member 38 which has a cavity in which the outer race ofthe bearing 37 is press fitted.

[0021] In accordance with the present invention, a sleeve 40 is pressfitted over the end of the spindle or dowel 20. The sleeve 40 is made ofmaterial, such as plastic, which can be drilled with a conventional wooddrill. If desired, the inner surface of the sleeve 40 may be formed withsplines (not shown) to aid in holding a sleeve 40 on the end of thespindle 20 and preventing relative rotation between the two members.

[0022] The illustrated sleeve 40 includes an integral drive pulley 45which receives the vacuum cleaner drive belt. The pulley 45 is shown asbeing formed with grooves 46 that coact with the drive belt (not shown)of the vacuum sweeper.

[0023] The embodiment illustrated in FIGS. 1-3 further includes onepiece plastic ferrules 50 at the ends of the brushroll 10. As shown,each ferrule 50 comprises a central hollow pin 51, a first radial wall52 extending outwardly from the end of the pin 51, an axially wall 53extending from the radial wall 52 to form a mouth 54 at the end of thepin, a second radial wall 55 extending outwardly from the axial wall 53,and a peripheral skirt 56 projecting from the radial wall 55 in adirection opposite to the axial wall 53. The skirt 56 is spaced radiallyoutwardly from the axial wall 53 to form a recess 57 that opens in anaxial direction opposite to the ferrule mouth 54. In the illustratedembodiment, a raised seat 58 is formed on the radial wall 52 in themouth 54 around the inside opening 59 of the pin 51.

[0024] When assembling the brushroll 10, the ferrule pin 51 is pressedinto the shaft hole 22 until the radial wall 52 bottoms against thebottom wall 23 of the spindle mouth 24. When the ferrule 50 is pressedinto the spindle, the spindle lip 26 and the end of the sleeve 40 arecaptured in the ferrule recess 57 between the skirt 56 and the wall 53.

[0025] Holes are drilled in the brushroll spindle 20 for the bristletufts 30. As shown in FIGS. 2 and 3, angled holes 41 are drilled throughthe ferrule skirt 36 and the sleeve 40 into the spindle 20 very near itsends. Angled end tufts 42 are fixed in the holes 41. The end tufts 42are angled from the perpendicular in a direction axially outwardly ofthe adjacent end of the spindle 20. Since the tufts 42 are located nearand extend beyond the ends of the spindle, they provide improved edgecleaning and create a wider cleaning path compared to prior art brushrolls. The sleeves 40 at the ends of the brushroll 10 prevent splittingof the wood spindle or dowel 20 when the holes 41 are drilled.

[0026] In a final assembly operation, a felt washer 60 may be adhered tothe outer surface of the ferrule wall 55, and the stub shafts 36 arepressed into the pins 51 until the end pieces 38 abut the seats 58 inthe mouths of the ferrules. Thus assembled, the members 38 aresurrounded by the axial walls 53 of the ferrules in order to guardagainst thread and dirt from entering the bearings. The sleeves 40 andthe ferrule skirts 56 prevent the spindle 20 from expanding because ofmoisture, and thereby act to maintain a tight fit of the ferrule pins 51and the stub shafts 36.

[0027]FIGS. 4 and 5 show an embodiment of the invention which is similarto the embodiment of FIGS. 1-3 except for the form of the drive pulley.In the embodiment of FIGS. 4 and 5, the sleeve is designated by areference numeral 40 a and the pulley by reference numeral 45 a. Thepulley option 45 a has cogs 47 that coact with a timing belt used insome vacuum cleaners as part of the brushroll drive.

[0028]FIG. 6 shows still another embodiment of the invention which issimilar to the embodiment of FIGS. 1-3 with the exception that theferrules 50 are eliminated. The sleeve 40 is press fitted over the endof the spindle 20 as previously described and the angled end tufts 42extend outwardly of the sleeve 40 beyond the ends of the spindle.

[0029] Many variations and modifications of the invention will beapparent to those skilled in the art in light of the above detaileddescription. Therefore, it is to be understood that, within the scope ofthe appended claims, the invention can be practiced otherwise than asspecifically disclosed.

In the claims:
 1. In a vacuum brushroll including a spindle andoutwardly extending bristle tufts carried by said spindle, theimprovement comprising end bristle tufts angled outwardly of saidspindle beyond its ends to provide improved edge cleaning and a widecleaning path upon rotation of said brushroll.
 2. In a vacuum brushrollincluding a spindle having a longitudinal axis of rotation, and bristletufts extending outwardly from the spindle, the improvement comprising amember around each end of said spindle, and angled end tufts extendingthrough said members, said end tufts being angled outwardly beyond theends of said spindle to provide a wide cleaning path and edge cleaningcapability upon rotation of said brushroll.
 3. The improvement asclaimed in claim 2 wherein a member at one end of said spindle has apulley belt drive surface.
 4. The improvement as claimed in claim 2 orclaim 3 wherein said members are sleeves.
 5. The improvement as claimedin claim 4 including a ferrule having a skirt surrounding an end portionof said sleeve, said angled end tufts extending outwardly through saidend portion of said sleeve and said skirt.
 6. In a vacuum cleanerbrushroll including a spindle having a longitudinal axis of rotation andbristle tufts extending outwardly of the spindle, the improvementcomprising a sleeve around an end portion of said spindle, a pulleyintegral with said sleeve, and angled tufts of bristles fixed in saidspindle and extending outwardly through said sleeve beyond said end ofsaid spindle to provide a wide cleaning path and an improved edgecleaning capability.
 7. The improvement as claimed in claim 6 includinga ferrule having a skirt surrounding an end portion of said sleeve, saidangled end tufts extending outwardly through said skirt.
 8. Theimprovement as claimed in claim 6 or claim 7 wherein said pulley is atimer belt pulley.
 9. The improvement as claimed in claim 6 or claim 7wherein said pulley has belt engaging grooves.